dap springless piston cylinder socket head bolts (dap1000, 1500). to connect the valve stem to the...

CM2-DAP100-2001

DAP Springless Piston Cylinder

User's Manual

NOTICEWhile the information in this manual is presented in good faith and believed to be accurate, Azbil Corporation disclaims any implied warranty of merchantability or fitness for a particular purpose and makes no express warranty except as may be stated in its written agreement with and for its customer.In no event shall Azbil Corporation be liable to anyone for any indirect, special or consequential damages. This information and specifications in this document are subject to change without notice.

© 2011–2013 Azbil Corporation All Rights Reserved.

CONTENTS

Chapter 1. Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1. Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2. Connection to the control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-3. Pneumatic piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-4. Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Chapter 2. Disassembly, Inspection, and Assembly of the Actuator . . . . 42-1. Detaching the actuator from the main unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-2. Disassembling the actuator (see Figures 5 and 6.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42-3. Inspecting components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112-4. Assembling the actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132-5. Assembling the valve body and air cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Chapter 3. Piping Configuration and Manual Operation Methods . . . . . 203-1. Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203-2. Manual/automatic operation methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

1

Chapter 1. Overview

1-1. StructureThis actuator includes a bonnet (top and bottom parts), a cylinder, staybolts, a yoke, a rod cover without side mounted manual operation lever (SHM), a snubber (with SHM), a hydraulic pump (with SHM).

For the appearance of the actuator, see Figures 1 and 2.

Figure 1. Appearance of DAP (without SHM)

Rod Cover

Eyenut

Bonnet Top

Staybolt

Cylinder

Bonnet Bottom

Yoke

2

Figure 2. Appearance of DAP (with SHM)

If an SHM is provided, the hydraulic pump has already been installed for manual operations and a stop valve for switching between manual and automatic operation is also included.This pump consists of a handle and a body, which includes an oil pocket, a plunger-type pump, a check valve, and a pressure balance adjustment valve (see Figure 3).

Note: There is an air-bleeder plug over the oil pocket, so install the control valve with the pump vertical or tilted so that the plug will always be above the oil pocket.

Figure 3. Hydraulic Pump

Snubber Bonnet

SHM (Side mounted manual operation lever)

Hydraulic Pump

Yoke

Bonnet Bottom

Cylinder

Bonnet Top

Staybolt

Eyenut Snubber Cylinder

HookPlug 2

Air-Bleeder Plug 4

200mm

50mm

Oil Pocket

Handle

Level gage(integrated with Air-Bleeder Plug 4)

3

1-2. Connection to the control valveThe actuator is connected to the control valve using the yoke tightening nuts (DAP560) or hexagon socket head bolts (DAP1000, 1500). To connect the valve stem to the piston rod, supply air into the actuator's bonnet bottom with the valve plug fully closed, check that the piston rod has risen about 3 mm, and then connect the valve stem to the piston rod using the stem connecter.Next, position them by loosening the small truss screw on the scale plate so that the indicator needle will be equal to the scale value for strokes (see Figure 4). Then, adjust the positioner according to the instruction manual. For further information, see the instruction manual for the control valve.

Figure 4. Section Where Control Valve Is Attached

1-3. Pneumatic pipingIf you use this as a control valve, install a double action positioner for piping.For information on the double action positioner, see the following instruction manuals.Electropneumatic positioner (AVP300/301 type) No. CM2-AVP300-2001Electropneumatic positioner (HEP25/26 type) No. OM2-8310-0300Pneumatic positioner (VPP02/03 type) No. OM2-8310-0300

1-4. Warning

WARNING• M20 eyenuts (5) and (17) on the top of the actuator may only be used when you hoist

the actuator itself, but are not to be used to hoist the actuator with the valve body attached. Using the eyenuts to hoist more than the actuator is dangerous.

• Installation position should be within ±45° from its vertical position. If the actuator and control valve is installed outside of this range, life of consumable parts (i.e. o-ring of sealing part) may be shortened.

Small truss screw

Scale Plate

Stem connecter

Valve stem

Indicator needle

Piston rod

Hexagon sockethead bolt

4

Chapter 2. Disassembly, Inspection, and Assembly of the Actuator

To disassemble, inspect, and assemble the actuator for periodic inspections, use the following procedures.

CAUTIONBecause individual components are heavy, use eyebolts and eyenuts. Hoist each component using a crane with the service taps of the components.

Items needed Where usedM12 eyebolt (x2) PistonChisel and hammer PistonM20 eyebolt (x2) Bonnet top/bottomRags For oil-drain in snubber Tray For oil-drain in snubber

2-1. Detaching the actuator from the main unitSee the instruction manual for the main unit.

2-2. Disassembling the actuator (see Figures 5 and 6.)Before disassembling the actuator, securely fasten the bottom of the yoke (31) or (40) with the actuator vertical (so that yoke (31) or (40) is on the bottom).

5

Table 1. DAP (without SHM) Table of ComponentsNo. Part Name Part Count No. Part Name Part Count

1 Rod cover 120 Hexagon socket head bolt

DAP560 42 Piston rod 1 DAP1000 83 Hexagon bolt 4 DAP1500 124 Spring washer 4

21 Spring washerDAP560 4

5 Eyenut 2 DAP1000 8

6 Spring washerDAP560 8 DAP1500 12DAP1000 16 22 Locknut 1DAP1500 24 23 Indicator needle 1

7 StayboltDAP560 4 24 Scale plate 1DAP1000 8 25 Small truss screw 2DAP1500 12 26 Spring washer 2

8 Hexagon nutDAP560 6 27 Hexagon nut 2DAP1000 14

28Stem connecter attachment 1a

DAP1500 22 28-1 Stem connecter 19 Instruction plate for eyenut 1 28-2 Hexagon bolt 4

10 Bonnet 2 29 Name plate 111 O-ring 3 30 Drive screw 412 O-ring 2 31 Yoke 113 Tape liner 4

32Hexagon bolt DAP560 1

14 Bushing 2Hexagon socket head bolt

DAP1000 815 Piston 1 DAP1500 816 O-ring 1

33Yoke tightening nut DAP560 1

17 Split ring 2 setsSpring washer

DAP1000 818 Plate tightening nut 1 DAP1500 819 Cylinder 1 34 Bushing 2

35 Hexagon socket head tapered plug 2

6

Figure 5. DAP (without SHM) Development Diagram of Components

For the DAP560

32

33

86353410

7

21

1

11

19

11

10

6

8

3435

2726

2524

12

31

5

6

9

7

6

8

20

2930

13

33

32

14

13

2

16

17

18

13

14

13

1222

23

28

3

4

11

15

7

Table 2. DAP (with SHM) Table of ComponentsNo. Part Name Part Count No. Part Name Part Count

1 Snubber bonnet 129

Hexagon socket head bolt DAP560 42 Piston rod 1 DAP1000 83 Locknut 1 DAP1500 12

4 StayboltDAP560 4

30Spring washer DAP560 4

DAP1000 8 DAP1000 8DAP1500 12 DAP1500 12

5 Hexagon nutDAP560 4 31 Locknut 1DAP1000 8 32 Indicator needle 1DAP1500 12 33 Scale plate 1

6 Spring washerDAP560 4 34 Small truss screw 2DAP1000 8 35 Spring washer 2DAP1500 12 36 Hexagon nut 2

7 O-ring 237

Stem connecter attachment 1a8 O-ring 1 37-1 Stem connecter 19 O-ring 1 37-2 Hexagon bolt 4

10 Snubber piston 1 38 Name plate 111 Snubber cylinder 1 39 Drive screw 412 Snubber piece 1 40 Yoke 113 O-ring 1

41Hexagon bolt DAP560 1

14 O-ring 3Hexagon socket head bolt

DAP1000 815 Tape liner 4 DAP1500 816 Bushing 2

42Yoke tightening nut DAP560 1

17 Eyenut 2Spring washer

DAP1000 8

18 Spring washerDAP560 8 DAP1500 8DAP1000 16 43 Bushing 2DAP1500 24 44 Stop valve 1

19 StayboltDAP560 4 45 Instruction plate for stop valve 1DAP1000 8

46 Hexagon boltDAP560 2

DAP1500 12 DAP1000 4

20 Hexagon nutDAP560 6 DAP1500 4DAP1000 14

47 Spring washerDAP560 2

DAP1500 22 DAP1000 421 Instruction plate for eyenut 1 DAP1500 4

22 Bonnet 2 48 Hydraulic wheel mounting plate top 1

23 O-ring 3 49 Hexagon bolt 424 Piston 1 50 Spring washer 425 O-ring 1

51Spacer DAP560 2

26 Split ring 2 sets Hydraulic wheel mounting plate bottom

DAP1000 127 Plate tightening nut 1 DAP1500 128 Cylinder 1 52 Hydraulic handle 1

8

Figure 6. DAP (with SHM) Development Diagram of Components

For the DAP560 51

30

43

433

9

47 46

5049

4950

48

52

44 45

36

33

34

46 47

40

1

5

6

10

8

11

7

12

13

20

18

33

24

23

2018

7

4

14

3839

15

42

41

16

15

2

25

26

27

15

16

1514

31

32

37

22

19

28

23

22

18

20

35

17

18

21

29

19

42

41

9

2-2-1. Without SHM (see Figure 5)1) Marking and protection • Place a mark for matching on the rod cover (1), bonnet top (10), cylinder (19),

bonnet bottom (10), and yoke (31). • Remove the indicator needle (23) and locknuts (22), and cover the thread part of the

piston rod (2) with vinyl tape to protect the O-ring (12) and sliding part (bushing (14), tape liner (13)) during disassembly.

2) Removing the rod cover (1) • Loosen and remove the hexagon bolts (3) at the top of the actuator, and then remove

the spring washers (4). • Lift the rod cover (1) vertically and remove it.3) Removing the bonnet top (10) and staybolts (7) • Loosen and remove the hexagon nuts (8) and eyenuts (5) which are used to fix the

bonnet top (10), and then remove the spring washers (6) and staybolts (7). • Hoist the bonnet top (10) vertically and remove it, and then remove the O-ring (11),

tape liners (13), and O-ring (12).4) Removing the piston rod (2) and piston (15) • Extract the piston rod (2) from the cylinder (19) with the piston (15) still attached,

and then remove the O-ring (11) at the outer circumference of the piston (15). • Put the extracted piston rod (2) with the piston still attached upside down on the

mount seat with a hole (which must be high enough so that the piston rod does not reach the surface below).

• Loosen and remove the plate tightening nuts (18), extract the piston rod (2) from the piston (15), and then remove the split ring (17) and O-ring (16).

5) Removing the cylinder (19), bonnet bottom (10), and yoke (31) • Remove the cylinder (19), and then remove the hexagon socket head bolts (20) that

fasten the bonnet bottom (10) to the yoke (31). • Hoist the bonnet bottom (10) vertically and remove it, and then remove the O-ring

(11), tape liners (13), and O-ring (12).

2-2-2. With SHM (see Figure 6)1) Marking and protection • Place a mark for matching on the snubber bonnet (1), snubber cylinder (11), snubber

piece (12), bonnet top (22), cylinder (28), bonnet bottom (22), and yoke (40). Remove the indicator needle (32) and locknuts (31), and cover the thread part of the piston rod (2) with vinyl tape to protect the O-ring (14) and sliding part (bushing (16), tape liner (15)) during disassembly.

2) Removing oil. Remove oil as follows, according to Figures 3 and 8. • Move the piston down to the bottom via the manual actuator with the actuator

upright, and then remove plug 2. • Remove joints A and B of the switch cock and then place a tray under the pipe outlet. • Close stop valve 2 and open stop valve 3 to supply air pressure to the bonnet bottom

(22), and then remove the oil by raising the snubber piston (10) to the top. • After that, slowly remove the air pressure that has been supplied to the bonnet

bottom.

10

CAUTION• A little oil will remain inside the snubber cylinder (11) and hydraulic piping. It is

impossible to completely remove all the oil. Therefore, cover the snubber piece (12) and hydraulic pipe opening with rags before disassembling the snubber cylinder (11) and hydraulic piping.

• Be sure to slowly remove the air pressure. Quick removal of the air pressure is very dangerous.

• For manual operations, see section 3.

3) Removing the snubber bonnet (1), snubber cylinder (11), and staybolts (4) • Loosen and remove the hexagon nuts (5) at the top of the actuator, and then remove

the spring washers (6). • Lift the snubber bonnet (1) vertically and remove it. • Remove the O-ring (7) that is mounted to the snubber bonnet (1). • Wipe off the oil remaining inside the snubber cylinder (11) with a rag. • Remove the staybolts (4) and then remove the snubber cylinder (11).4) Removing the snubber piston (10) and snubber piece (12) • Supply air pressure to the bonnet bottom (22). With the pneumatic cylinder fully

opened, loosen and remove the locknuts (3) that fix the snubber piston (10), and then remove the snubber piston (10), and O-rings (8) and (9).

• After that, slowly remove the air pressure.

CAUTION• Be sure to slowly remove the air pressure. Quick removal of the air pressure is very

dangerous.

• Remove the snubber piece (12), the O-rings (7) and (14) that were mounted, and the O-ring (13).

5) Removing the bonnet top (22) and staybolts (19) • Loosen and remove the eyenuts (17) and hexagon nuts (20) that are used to fix the

bonnet top and bottom (22), and then remove the spring washers (18) and staybolts (19).

• Hoist the bonnet top (22) vertically and remove it, and then remove O-ring (23), tape liners (15), and O-ring (14).

6) Removing the piston rod (2) and piston (24) • Extract the piston rod (2) from the cylinder (28) with the piston (24) still attached,

and then remove the O-ring (23) at the outer circumference of the piston (24). • Put the extracted piston rod (2) with the piston still attached upside down on the

mount seat with a hole (which must be high enough so that the piston rod does not reach the surface below).

• Loosen and remove the plate tightening nuts (27), extract the piston rod (2) from the piston (24), and then remove the split ring (26) and O-ring (25).

7) Removing the cylinder (28), bonnet bottom (22), and yoke (40) • Remove the cylinder (28), and then remove the hexagon socket head bolts (29) that

fasten the bonnet bottom (22) to the yoke (40). • Hoist the bonnet bottom (22) vertically and remove it, and then remove O-ring (23),

tape liners (15), and O-ring (14).

11

2-3. Inspecting componentsMake sure that the disassembled components have no defects. The service life of the DAP is 10 years when limited service life components are used following recommended replacement cycle. Although components have been manufactured to tolerate prolonged use, you should repair or replace components as necessary if they have any defects.Table 3 lists the components with limited service life. Replace components according to this table.

Table 3. List of Components with Limited Service Life (without SHM)

No. Part Name Part Number Recommended Replacement Cycle

Remarks Part Count

11 O-ring DAP560 82592232-296 5 years R e p l a c e during dis-assembly

3

DAP1000 80256742-896

DAP1500 80228578-196

12 O-ring DAP560 82592225-396 2

DAP1000 82592225-396

DAP1500 82592226-296

13 Tape liner DAP560 82601995-001 4

DAP1000 82601995-001

DAP1500 82601995-002

16 O-ring DAP560 82592235-596 R e p l a c e during dis-assembly

1

DAP1000 82592235-596

DAP1500 82592235-796

12

Table 4. List of Components with Limited Service Life (with SHM)

No. Part Name Part Number Recommended Replacement Cycle

Remarks Part Count

7 O-ring DAP560 82592237-796 5 years R e p l a c e during dis-assembly

2

DAP1000 82592237-796

DAP1500 82592238-796

8 O-ring DAP560 82592228-796 1

DAP1000 82592228-796

DAP1500 82592229-896

9 O-ring DAP560 82592235-596 1

DAP1000 82592235-596

DAP1500 82592235-796

13 O-ring DAP560 82592236-996 1

DAP1000 82592236-996

DAP1500 82592237-696

14 O-ring DAP560 82592225-396 3

DAP1000 82592225-396

DAP1500 82592226-296

15 Tape liner DAP560 82601995-001 4

DAP1000 82601995-001

DAP1500 82601995-002

23 O-ring DAP560 82592232-296 R e p l a c e during dis-assembly

3

DAP1000 80256742-896

DAP1500 80228578-196

25 O-ring DAP560 82592235-596 1

DAP1000 82592235-596

DAP1500 82592235-796

13

2-4. Assembling the actuatorBefore assembly, clean the components with a rag, etc. When assembling the actuator, be sure to prevent foreign matter from enterting the sliding section.

Apply supplementary material to the O-rings, tape liner, inner surface of the cylinder without dirt. For details on the supplementary materials and application locations, see Tables 5 and 6.

For information on tightening screws, see Tables 7, 8, 9, and 10, and apply the specified tightening torque.

Refer to the marks that you made before disassembly in order to remember the directions in which components should be installed.

Table 5. List of Supplementary Materials (without SHM)

No. Part Name Applied Location and Supplementary Material

3 Hexagon bolt Thread partNEVER-SEEZBostik, Inc.

5 Eyenut

8 Hexagon nut

18 Plate tightening nut

20 Hexagon socket head bolt

22 Locknut

23 Indicator needle

28-1 Stem connecter

28-2 Hexagon bolt

32 Hexagon bolt

Hexagon socket head bolt

33 Yoke tightening nut

11 O-ring The entire sliding part of components, mounting slotsPlastilube No. 3SULFCO, INC.

12 O-ring

13 Tape liner

16 O-ring

19 Inner surface of the cylinder

Nichimoly C PowderShin-Etsu Chemical Co., Ltd., G40-M

34 Bushing Tapered thread partNIPPON VALQUA INDUSTRIES, LTD., Seal35 Hexagon socket head

tapered plug

CAUTION• Before assembly, clean the O-rings, tape liners, and O-ring slots, and then apply

lubricant to them.• Note that any flaws or foreign matter on the bushing, insufficient lubrication, or

incorrect installation may affect performance.• Thoroughly apply molybdenum disulfide to the inner surface of the cylinder. Then,

lightly apply Plastilube No.3 to it.

14

Table 6. List of Supplementary Materials (with SHM)

No. Part Name Applied Location and Supplementary Material

3 Locknut Thread partNEVER-SEEZBostik, Inc.

4 Staybolt

5 Hexagon nut

17 Eyenut

20 Hexagon nut

27 Plate tightening nut


31 Locknut

32 Indicator needle

37-1 Stem connecter

37-2 Hexagon bolt

41 Hexagon bolt

Hexagon socket head bolt

42 Yoke tightening nut

46 Hexagon bolt

49 Hexagon bolt

7 O-ring The entire sliding part of components, mounting slotsPlastilube No.3SULFCO, INC.

8 O-ring

9 O-ring

13 O-ring

14 O-ring

15 Tape liner

23 O-ring

25 O-ring

28 Inne r su r face o f t he cylinder

Nichimoly C PowderShin-Etsu Chemical Co., Ltd., G40-M

43 Bushing Tapered thread partNIPPON VALQUA INDUSTRIES, LTD., Seal

Hydraulic oil Nippon Petrochemicals Co., Ltd Super Hyrando 32Equivalent product: COSMO OIL Co., Ltd Swaloop R032

Amount of Hydraulic Oil (L)Stroke (mm) DAP560 DAP1000 DAP1500

50 or less 3 3 575, 100 4 4 6.5

15

Table 7. List of Tightening Torques (without SHM) (N·m)

No. Part Name DAP560 DAP1000 DAP1500

Screw Size Tightening Torque



3 Hexagon bolt M20 130 to 175 M20 130 to 175 M20 130 to 175

8 Hexagon nut M20 130 to 175 M20 130 to 175 M20 130 to 175


M20 250 to 340 M20 250 to 340 M20 250 to 340

22 Locknut M36×1.5 480 M36×1.5 480 M42×1.5 650

28-2 Hexagon bolt M14 80 to 110 M14 80 to 110 M20 130 to 175

32 Hexagon socket head boltHexagon bolt

M12 52 to 70 M22 160 to 215 M22 160 to 215

Table 8. List of Tightening Torques (with SHM) (N·m)





3 Locknut M36×1.5 480 M36×1.5 480 M42×1.5 650




M20 250 to 340 M20 250 to 340 M20 250 to 340

31 Locknut M36×1.5 480 M36×1.5 480 M42×1.5 650



M12 52 to 70 M22 160 to 215 M22 160 to 215



Tables 7 and 8 show Tightening torque of bolts and nuts when these are made with stainless steel.

16

Table 9. List of Tightening Torques (without SHM) (N·m)








M20 130 to 175 M20 130 to 175 M20 130 to 175

22 Locknut M36×1.5 480 M36×1.5 480 M42×1.5 650



M12 35 to 40 M22 180 to 240 M22 180 to 240

Table 10. List of Tightening Torques (with SHM) (N·m)





3 Locknut M36×1.5 480 M36×1.5 480 M42×1.5 650




M20 130 to 175 M20 130 to 175 M20 130 to 175

31 Locknut M36×1.5 480 M36×1.5 480 M42×1.5 650



M12 35 to 45 M22 180 to 240 M22 160 to 215



Tables 9 and 10 show Tightening torque of bolts and nuts when these are made with carbon steel.

17

2-4-1. Without SHM (see Figure 5)1) Assembling the piston (15), piston rod (2) • Put the piston (15) upside down on the mount seat with a hole and mount O-ring

(11). • Insert the piston rod (2) into the piston (15), and mount the O-ring (16) and split ring

(17). • Secure them with the plate tightening nuts (18).2) Assembling the bonnet bottom (10), yoke (31), cylinder (19), and piston rod (2) • Place the bonnet bottom (10) with O-rings (11), (12), and tape liner (13) mounted

on the yoke (31), and adjust them so that the bolt holes of the yoke (31) engage the thread holes of the bonnet bottom (10). Then, secure them using the hexagon socket head bolts (20) with the spring washer (21).

• Install the cylinder (19) and then install the piston rod with the piston (2) (which was assembled in 1).

3) Assembling the bonnet top (10) and staybolt (7). • Install the bonnet top (10) with O-rings (11), (12), and tape liner (13) mounted so

that the holes of the bonnet top (10) engage the holes of the bonnet bottom (10). • Mount the staybolt (7), spring washer (6), and eyenut instruction plate (9) on it, and

secure them with eyenuts (5) and hexagon nuts (8).4) Installing the rod cover (1) • Install the rod cover (1) so that the holes of the rod cover (1) engage the thread holes

of the bonnet top (10). • Secure them using hexagon bolts (3) with spring washers (4).5) Installing the locknut (22) and indicator needle (23) • Install the locknuts (22) and indicator needle (23) onto the piston rod (2).

2-4-2. With SHM (see Figure 6)1) Assembling the piston (24), piston rod (2) • Put the piston (24) upside down on the mount seat with a hole and mount O-ring

(23). • Insert the piston rod (2) into the piston (24), and mount O-ring (25) and split ring

(26). • Secure them with plate tightening nuts (27).2) Installing the bonnet bottom (22), yoke (40), cylinder (28), and piston rod (2) • Place the bonnet bottom (22) with O-rings (14), (23), and tape liner (15) mounted

on the yoke (40), and adjust them so that the bolt holes of the yoke (40) engage the thread holes of the bonnet bottom (22). Then, secure them using the hexagon socket head bolts (29) with the spring washer (30).

• Install the cylinder (28) and then install the piston rod with the piston (2) (which was attached in 1).

3) Assembling the bonnet top (22) and staybolt (19). • Install the bonnet top (22) with O-rings (14), (23), and tape liner (15) mounted so

that the holes of the bonnet top (22) engage the holes of the bonnet bottom (10). • Mount the staybolt (19), spring washer (18), and eyenut instruction plate (21) on it,

and secure them with eyenuts (17) and hexagon nuts (20).4) Installing the snubber piece (12) • Mount O-ring (13) on the bonnet top (22), and then install the snubber piece (12)

with O-rings (7) and (14) mounted.

18

5) Assembling the snubber piston (10) and snubber cylinder (11) • Apply air pressure to the bonnet bottom (22), and install the snubber piston (10) with

O-rings (8), (9) mounted to the piston rod (2) with the air cylinder fully open, and then secure them with locknuts (3).

• After that, slowly remove the air pressure.

CAUTIONBe sure to slowly remove the air pressure. Quick removal of the air pressure is very dangerous.

• Install the snubber cylinder (11).6) Assembling the snubber bonnet (1) and staybolt (4) • Adjust the snubber bonnet (1) with O-ring (7) mounted so that the holes of the

bonnet engage the thread holes of the bonnet top (22), and then secure them. • Insert the staybolt (4) into the bolt hole of the snubber bonnet (1) and thread hole of

the bonnet top (22), and secure them with spring washers (6) and hexagon nuts (5).7) Assembling the locknut (31) and indicator needle (32) • Install the locknuts (31) and indicator needle (32) onto the piston rod (2).8) Lubrication • Set up the cylinder vertically and perform the following, referring to Figures 3 and 7.

CAUTIONDo not remove plugs 1 and 4 at the same time. If you remove them, oil may flow out of plug 4.

(1) Move the piston down to the bottom position with (A) Automatic operation described in Table 1, remove plugs 1 and 2, and then inject sufficient oil into the hole of plug 1. After that, close plugs 1 and 2.

(2) Remove plugs 3 and 4 with the state (C) “Manually open the valve” in Table 1, also open cock 2.

(3) Inject an amount of oil into the hole of plug 4 up to half of the oil pocket and then send oil to the bottom of the piston by operating the hydraulic pump with stop valve 3 opened. Then, close plug 3 after oil starts flowing out from the hole of plug 3.

(4) Then, operate the hydraulic pump, and repeat the operation of Fully Open <=> Fully Closed once or twice to remove the remaining oil in the hydraulic piping.

(5) Lastly, operate the hydraulic pump and move the piston up to the top, and then use a level gage, which is attached to plug 4, to fill the oil pocket with oil until 200 mm of air remains at the top. Then, close plug 4 and cock 2.

During this operation, make sure that the piston is at the top. Do not perform any operations if the piston is not in the top position.

CAUTIONHow to remove the hook of the hydraulic pumpWhile pulling the hook with one hand in the direction of removal, remove the handle with your other hand as you push the handle toward the oil pocket.At this time, do not loosen hook 2.

19

2-5. Assembling the valve body and air cylinder2-5-1. For when a SHM is not provided

1) Lift the piston cylinder by using eyenut (5) and place it on the valve body. For the DAP560 Tightly fix the yoke (31) to the body with yoke tightening nuts (33), and tighten the

hexagon bolts (32). For the DAP1000 and 1500 Tightly fix the yoke (31) to the body using hexagon socket head bolts (32) with a

spring washer (33) mounted.2) Make sure that the valve system is fully closed. Then, apply air pressure to the bonnet

bottom (10) so that the indicator needle points the fully closed position.3) Mount the screws of the stem connecter (28) so that they engage the threads of the

piston rod (2) and valve stem.4) Install the positioner and then run the pneumatic piping.

2-5-2. With SHM1) Lift the piston cylinder by using eyenut (17) and place it on the valve body. For the DAP560 Tightly secure the yoke (40) to the body with yoke tightening nuts (42), and tighten

the hexagon bolts (41). For the DAP1000 and 1500 Tightly secure the yoke (40) to the body using hexagon socket head bolts (41) with a

spring washer (42) mounted.2) Make sure that the valve system is fully closed. Then, apply air pressure to the bonnet

bottom (22) so that the indicator needle points approximately 2 to 3 mm above the fully closed position.

3) Mount the screws of the stem connecter (37) so that they engage the threads of the piston rod (2) and valve stem.

4) Install the positioner and then run the pneumatic piping.

20

Chapter 3. Piping Configuration and Manual Operation Methods

3-1. Piping

Figure 7 Piping System Diagram

Switch Cock

N · T OPEN

MAN

Switch Cock CircuitSwitch Cock

SHUT

Hydraulic Pump

Plug 4

Plug 2

Plug 3

Plug 1

Air Cylinder

HydraulicCylinder

Hydraulic PipingStop Valve 2

Stop Valve 3

Stop Valve 4

Pneumatic Piping

Positioner

※1

※1

Supply Air Pressure

Input Signal

Direct action: Outward movement of the piston rod in response to an increase in input signalReverse action: Inward movement of the piston rod in response to an increase in input signal

Cock 2A

T

P

B

N·L

OPEN

SHUT

A

T N ·TOPEN

SHUT

T

P

P

B

A B

21

3-2. Manual/automatic operation methods3-2-1. Piping status

There are four statuses of piping depending on the type of operation.(A) Automatic operation(B) Manually close the valve(C) Manually open the valve(D) Lock it in any position If you change the above status, be sure to change it along the directions of arrows (1)

to (6) shown in Figure 8. Therefore, if you change the current status to a new status, change it to (D) Lock it in any position and then change it to the new status. After manual operations, change it back to (D) Lock it in any position for safety.

Table 9 shows the settings of piping equipment in each status.

Figure 8. Operation Flow

Table 9. Piping Equipment Settings Operation type

Piping Equipment Name

(A)Automatic operation

(B)Manually close

the valve

(C)Manually open

the valve

(D)Lock it in

any position

Switch cock N/L position SHUT position OPEN position N/L position

Stop valve 2 OPEN SHUT SHUT SHUTStop valve 3 OPEN OPEN when the manual pump is operated.

SHUT when the manual pump is not operated.(See Section 3.2.2 (3), (5).)

SHUT

Stop valve 4 SHUT OPEN OPEN OPEN

3-2-2. Switching operation procedureFor switching operations (1) to (6) in Figure 8, see Figures 2, 3, and 7. Be sure to follow the operation procedure below.

CAUTIONThe operation procedures described here allow for the force that the valve receives from fluid. Therefore, never perform any operations except the operations described below.Before and after a switching operation, make sure that the piping equipment settings satisfy Table 1.

(1)

(A)Automaticoperation

(D)Lock it at any position

(B)Manually close the valve

(C)Manually open the valve

(2)

(3)

(4)

(5)

(6)

22

(1) (A) Automatic operation (D) Lock it in any position (1)-1 Set a supply air pressure to the positioner and input signals. (1)-2 Fully close stop valves 2 and 3. (1)-3 Fully open stop valve 4.

(2) (A) Automatic operation(D) Lock it in any position (2)-1 Set a supply air pressure to the positioner and input signals. (2)-2 Fully close stop valve 4. (2)-3 Gradually open stop valves 2 and 3 until they are fully open.

CAUTIONSlowly open valves while looking at the valve position pointer to avoid quickly opening the valve.

(3) (B) Manually close the valve(D) Lock it in any position (3)-1 Move the switch cock to the SHUT position. (3)-2 Slowly open stop valve 3. Operate the hydraulic pump to close the valve

with stop valve 3 fully open. Fully close stop valve 3 at any valve opening.

CAUTIONSlowly open valves while looking at the valve position pointer to avoid quickly opening the valve.Do not operate the hydraulic pump with stop valve 3 fully closed.

(4) (D) Lock it in any position(B) Manually close the valve (4)-1 Fully close stop valve 3. (4)-2 Move the switch cock to the N/L position.

(5) (C) Manually open the valve(D) Lock it in any position (5)-1 Move the switch cock to the OPEN position. (5)-2 Slowly open stop valve 3. Operate the hydraulic pump to open the valve

with stop valve 3 fully open.

CAUTIONSlowly open valves while looking at the valve position pointer to avoid quickly opening the valve.Do not operate the hydraulic pump with stop valve 3 fully closed.

(6) (D) Lock it in any position(C) Manually open the valve (6)-1 Fully close stop valve 3. (6)-2 Move the switch cock to the N/L position.

Document Number: CM2-DAP100-2001

Document Name: DAP Springless Piston Cylinder User's Manual

Date: 1st edition: Dec. 2011 2nd edition: Jan. 2013Issued/Edited by:

dap springless piston cylinder socket head bolts (dap1000, 1500). to connect the valve stem to the...

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